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Going to start this off by stating that in no way am I a welder/fabricator, so don't judge too hard haha I do work for a great company on the general construction side of things and the other half of the company is fabrication which allows me to play with toys.
The idea for the build was to use a tool box I've had lying around for quite a while and mount it without actually attaching it to the bed, make full length bed rails for protection/add a secondary 7-way/removable material rack..../whatever else comes to mind. Got 2 inches between the bed and tool box for boots or whatever else, wish I could have made it larger to reach the hooks in the bed but greater minds at Ford have made it difficult to find Super Crew 250's with a long box, and bed space is minimal. Going to remedy this with hooks on the rails.
I plan to blend every weld and rivet our companies logo after it is powdercoated. Trying to figure our some quality LED brake, reverse and small amber marking lights for the side of the rack if anybody has any input. Also thinking about color matching as close as I can, going maroon (Texas A&M, Gig 'Em) or maybe a bronze color. Whatever color is chosen, bumpers will match in the future, it's very important
That looks great , I'm glad to see you integrated the L channel to protect the bed rails . I have build a few in steel and now seem to use aluminum these days .
That looks great , I'm glad to see you integrated the L channel to protect the bed rails . I have build a few in steel and now seem to use aluminum these days .
That rack is killer Greg! Initially the rails were designed to be separate from the rack and bolted on with some 1/2" or larger grade 8 hardware but after talking to some more talented friends and coworkers, landed on just welding the whole dang thing together. I would have loved aluminum, but my boss told me to order the steel on the company dime so didn't want to look a gift horse in the mouth. I have TIG welded some heavy walled aluminum but MIG on steel is more comfortable for now. Could keep practicing, sell the thing on Craigslist and step up to aluminum.
Originally Posted by Deuce40s
That looks damn good. Don't be ashamed of using a grinder. I'd rather have a deep ugly weld than dimes stacked on the surface.
Are you planning out your wire chase so the wires are hidden when you finish?
Thanks Deuce! Planned on blending all the welds for a cleaner appearance from the get go, it's always bothered me when you look at expensive bumpers and headache racks built from well respected companies and they're covered in boogery welds. My welds may not be all dimes (some pennies and nickles thrown in there ) but I know I got good penetration and adhesion at least.
As far as wiring goes, that's exactly what I'm going to do. Make 2 separate looms, one that enters the cab through the port hole, along with cb and uhf/vhf antenna cables, connected to the second that is run for power with Deutsch DTM style connectors. The reverse and brake lights will be completely housed to maintain the clean appearance.
Are you planning out your wire chase so the wires are hidden when you finish?
Oh, duh, or just make 2 shorter looms and tap into power going to the taillights, which would make much more sense, since I'm already going to be tapping into the trailer connections for the in bed 7-way. I'm home sick, brain isn't firing on all cylinders.
I did a little more bracing , also a 360 degree tie down system for trucks , its pretty budget friendly and they have it in Mc Master Carr under truck tie down systems , you can move the tie downs around .I just used a product called Raptor Liner , not as good as the Poly- Urethra bed liner sprayed but pretty good stuff .
I did a little more bracing , also a 360 degree tie down system for trucks , its pretty budget friendly and they have it in Mc Master Carr under truck tie down systems , you can move the tie downs around .I just used a product called Raptor Liner , not as good as the Poly- Urethra bed liner sprayed but pretty good stuff .
how does the section at the tailgate work? Hinged or bolted?
That piece of metal across was to just hold the aluminum in place during the lifting and coating . I made a Aluminum edge that covers the entire tailgate . No hole are drilled for this rack uses the factor holes .
I'm actually working on another one for my F-450 same Aluminum 3"x3" Headache tubes .
I just use a 7pin trailer tap adapter , the one that has the 4 pin on the side and put it inline to either the 7pin for the 5th wheel or the bumper , Use the LED Trailer oval lights , they draw just about nothing in amperage and look great .
That piece of metal across was to just hold the aluminum in place during the lifting and coating . I made a Aluminum edge that covers the entire tailgate . No hole are drilled for this rack uses the factor holes .
I'm actually working on another one for my F-450 same Aluminum 3"x3" Headache tubes .
I just use a 7pin trailer tap adapter , the one that has the 4 pin on the side and put it inline to either the 7pin for the 5th wheel or the bumper , Use the LED Trailer oval lights , they draw just about nothing in amperage and look great .
That tie down system is pretty slick, I'll look into it, though I would only be able to use it on two sides. Those gussets look great, did you water jet everything? And what brand LEDs do you like? I've been going back and forth on a bunch of stuff but I'm a name brand kind of guy when I want something to last.
Made some good progress this weekend. Adjusted the height and fixed the sides to where I like them. There's a ~3/64th difference between the driver side and passenger but can't nobody tell the way the bed lines up with the cab anyways. Now just blend and fill, blend and fill, blend and fill...then weld up the light box and louvers.
Good Lord, I'm way behind on updates and schedule. Would love to give y'all a list of excuses but I heard those are like *******s, and pretty sure we know how the rest of that goes haha Got a few D rings welded on for future material rack, square tubing for that rack to sit in plus a little box for a 7 way trailer plug inside the bed and mount for CB antenna. Have done some more clean up on the mill scale and such, probably going to end up using Bondo for imperfections, sanding for a clean surface and painting it myself instead of having it powder coated. Partially because the finish I was wanting would be pretty expensive to powder coat (multiple coat process), partially because I'm getting impatient and lastly because I saw a headache rack while out on the road the other day that really caught my eye so might just rock this one for a bit in the hopes of building another and selling this one.
) but I know I got good penetration and adhesion at least.
